System and method for compacting materials in open top transport conveyance

Abstract

A compacting system compacts particulate matter in open-top railroad gondola cars rolling on rails. The compacting system comprises a compacting station adjacent the rails and a scanning system that scans the gondola cars as they move along the rails toward the compacting station. The scanning system transmits data of the gondola car to an electronic control system. The compacting station has at least one compaction member, e.g., a plate structure or a roller, configured to contact an upper surface of the particulate matter in the gondola cars. The electronic control system controls the compacting station so that the compaction member engages with and applies force to the upper surface of the particulate matter in the gondola car so as to compress the particulate matter in the gondola. A method for compacting particulate matter in a gondola car is also shown.

What is claimed is: 
     
       1. A compacting system for compacting particulate matter in open-top railroad gondola cars rolling on rails, the compacting system comprising:
 a first compacting station adjacent the rails, a second compacting station, and a third compacting station; 
 a scanning system that scans each of the gondola cars as said gondola cars move along the rails toward the compacting station, said scanning system transmitting data of each gondola car to an electronic control system; and 
 the first compacting station having a first compaction member configured to contact an upper surface of the particulate matter in each of the gondola cars; 
 the electronic control system controlling said compacting station so that the first compaction member engages with and applies force to the upper surface of the particulate matter in each gondola car so as to compress said particulate matter in each gondola cal; 
 wherein the first compacting member includes a first generally planar plate structure engageable with the particulate matter, the first plate structure being operatively associated with a vibration system imparting vibration to the first plate structure as the first compaction member compacts the particulate matter; 
 wherein the second compacting station includes a second compacting member including a second plate structure, the second compacting station engageable with the upper surface of the particulate matter; 
 wherein the third compacting station includes a third compacting member including a third plate structure, the third compacting station engageable with the upper surface of the particulate matter, and 
 wherein the plate structures of each of the compacting members are supported sequentially relative to the rails with the first plate structure compacting the particulate matter to a first height, the second plate structure compacting the particulate matter to a second height lower than the first height, and the third plate structure compacting the particulate matter to a third height that is lower than the second height. 
 
     
     
       2. The compacting system of  claim 1  wherein the particulate matter is coal. 
     
     
       3. The compacting system of  claim 1  wherein the scanning station includes a laser or ultrasonic detection system that detects when each of the gondola cars passes a location on the rails. 
     
     
       4. The compacting system of  claim 1  wherein the scanning station includes an RFID reader that interrogates a respective RFID tag on each of the gondola cars, and the data transmitted to the control system includes RFID data derived from the interrogation of the RFID tag, the control system accessing a database using said RFID data and obtaining therefrom railcar data, said railcar data being used to control operation of the compacting station so as to clear a forward wall of the gondola car as said gondola car moves past the compaction station on the rails. 
     
     
       5. The compacting system of  claim 1  wherein the compacting station comprises at least one pillar structure on a side of the rails supporting the compacting member above the rails for reciprocal generally vertical movement between an upper position wherein the compacting member is high enough to permit a locomotive drawing the cars and the front and rear walls of the gondola cars to pass thereunder, and a lower position wherein the compacting member engages the upper surface of the particulate matter and compacts the particulate matter. 
     
     
       6. The compacting system of  claim 1  wherein the plate structures are pivotally supported on a frame of the compacting station, and the frame is supported for reciprocal generally vertical movement of the compaction station. 
     
     
       7. The compacting system of  claim 1 , wherein the force applied on the particulate matter from the compaction member is in the range of 2 to 50 pounds per square inch (psi). 
     
     
       8. The compacting system of  claim 1 , wherein the force applied on the particulate matter from the compaction member is in range of 7 to 19 pounds per square inch. 
     
     
       9. The compacting system of  claim 1 , wherein the force applied on the particulate matter from the compaction member is about 8 psi. 
     
     
       10. The compacting system of  claim 1 , wherein the control system includes a computer or a programmable logic controller. 
     
     
       11. A compaction station comprising:
 a support structure supporting a compaction member extending laterally across and above a pair of rails configured to carry railcars; 
 said compaction member being supported for reciprocal vertical movement between an upper position and a lower position; 
 the upper position being such that a locomotive and a front wall and a back wall of a gondola car can pass on the rails under the compaction member; and 
 the lower position being such that the compaction member in the lower position engages and applies a downward compacting force to a surface of particulate matter in a filled gondola car with an open top cargo space when the gondola car cargo space is below the compaction member; and 
 the compaction member being of a lateral dimension small enough that the compaction member fits into the cargo space of the gondola; 
 wherein the support structure comprises at least a pair of pillar structures, each on a respective side of the rails, and a frame supported therebetween above the rails, the compacting member including a plate structure supported on and movable with the vertically movable frame structure; and 
 wherein the plate structure includes a center plate and a pair of flanges each extend obliquely downward and laterally outward from a respective lateral edge of the center plate, the center plate and the flanges all engaging the particulate matter and compacting the particulate matter so as to have a crown shape defined by the center plate and the flanges. 
 
     
     
       12. The compaction station of  claim 11 , wherein the compaction member includes a vibration system that causes the compaction member to vibrate at least when in contact with the particulate matter in the gondola car. 
     
     
       13. The compaction station of  claim 11 , wherein the frame further supports a second plate structure having a center plate and two obliquely downward extending lateral flanges, said second plate structure contacting the particulate matter forward relative to the gondola of the first plate structure and compressing the particulate matter to a height lower than the crown shape produced by the first plate structure. 
     
     
       14. The compaction station of  claim 11 , wherein the plate structure has a rearward portion pivotally connected with the frame, the plate structure pivoting downward in the lower position. 
     
     
       15. The compaction station of  claim 11 , wherein the compaction member is a roller. 
     
     
       16. The compaction station of  claim 11 , wherein the support structure has a spray apparatus thereon that sprays a flying-dust reduction fluid onto the particulate matter after compaction thereof. 
     
     
       17. The compaction station of  claim 11 , wherein movement of the compaction member is controlled by an electronic controller comprising a computer or a programmable logic controller.